Hybrid performance

Hybrid performance

Hybrid performance – Double mono-rotary line with energy recovery system

Client profile: Large manufacturing facility focused on maintaining stable quality parameters in high-volume production.

The project was implemented for a high-volume production company specialising in the production of parts with complex geometry. A key aspect of the company’s activity is ensuring the highest quality of aesthetically pleasing coatings (especially in white) and maintaining operational continuity despite the very dynamic colour changes.

Strategic goals: Eliminating bottlenecks and separating quality processes

The main goal of the investment was to create a system that would eliminate downtime caused by colour changes while maintaining high efficiency at a relatively low line speed.

Key performance indicators (KPIs) for the investment:

  • Operational continuity: Possibility of painting two product series in parallel (white + other colours).
  • Elimination of downtime: Reduction of waiting time for colour changes by 15–20 minutes.
  • Process efficiency: Achieving total flow rates above 5 m/min at an ergonomic pace for operators.
  • Energy efficiency: 12% reduction in energy consumption thanks to residual heat recovery.

Challenge: Bottlenecks during colour changes

In standard monorotary lines with booths arranged in series, each colour change forces the process to stop, generating significant time losses. The client needed a solution that would allow for the separation of white (which requires the highest purity) from the rest of the colour palette, while maintaining a compact line footprint and optimal technology costs.

Ecoline solution: Selective monorotary conveyor with process path selection function

Instead of building an expensive Power & Free system, Ecoline proposed a bridging solution: a double monorotary line operating at 2 x 2.5 m/min.

1. Two independent conveyor tracks

This system ensures production flexibility. After pre-treatment and drying, the lines are separated into two booths, allowing for simultaneous painting with different colours. The parts then go to separate polymerisation ovens and are finally combined in the cooling zone.

2. Shared surface preparation tunnel and siphon ovens

Both lines share a common, integrated surface preparation tunnel. The tunnel has a double pass window and independent spray systems for each lane. Siphon ovens provide excellent thermal insulation, minimising energy loss during part entry and exit.

3. Clean Room application

The painting robots were placed in a controlled environment (Clean Room). Full control of temperature, humidity, and airflow ensures laboratory-quality application and consistent coating results year-round, eliminating the impact of external conditions on the quality of the finish.

4. Heat pumps – Residual energy recovery

An innovative feature is the system for recovering residual energy from the line area (engines, fans, and losses through housing). The heat pump captures this dispersed, low-grade heat and converts it into high-grade energy, which is used to heat water in the process tanks. This allows for significant savings in gas and electricity.

Measurable investment results

Continuous operation:

With the conveyor’s fork, a colour change in one cabin does not affect the performance of the other, allowing the pace of serial production to be maintained.

Colour separation:

A dedicated white booth guarantees a clean finish and flawless appearance of the final coating.

Inteligentne sterowanie RFID:

System automatycznie rozpoznaje zawieszone detale i dobiera odpowiednie receptury dla pieców, kabin i tunelu przygotowania powierzchni.

Cost optimisation:

The functionality of two independent painting processes was achieved with significantly lower investment costs than with P&F systems.

“A double monorotary line is a cost-effective solution for plants with a wide range of colours. The use of a track switch and parallel cabins eliminates the weakest point of standard systems – downtime for changeovers – while ensuring high efficiency at relatively low conveyor speeds.”

Ecoline Engineering Team

Summary: A modern paint shop without compromise

The design of this dual monorotary line demonstrates that thoughtful engineering allows for the creation of a flexible production system within a reasonable budget. Thanks to the combination of automation, robotics, Clean Room and innovative heat recovery using heat pumps, the client gained a line that sets new standards of efficiency and process control.